Function Module for Electrical Applications

Abstract

A function module for electrical applications and method of making a function module for electrical applications. The function module includes: a functional member having a piercing area with at least one aluminum conductor trace; and an electrical connector having at least one piercing member. The at least one piercing member is configured to pierce through the at least one aluminum conductor trace in an electrically conductive manner and provide a form-fit connection between the functional member and the electrical connector within the piercing area. The functional member and the electrical connector are joined together within the piercing area by means of a solder connection.

Claims

1) A function module for electrical applications, comprising: a functional member having a piercing area with at least one aluminum conductor trace; and an electrical connector having at least one piercing member, wherein the at least one piercing member is configured to pierce through the at least one aluminum conductor trace in an electrically conductive manner and provide a form-fit connection between the functional member and the electrical connector within the piercing area; wherein the functional member and the electrical connector are joined together within the piercing area by means of a solder connection.

2) The function module according to claim 1, wherein the solder connection is based on a surface activation composition comprising: an aqueous solvent or a mixed aqueous solvent; and/or an organic amine; and/or a fatty acid; and/or a filler selected from a group consisting essentially of Sn, Ag, Zn, Cu, In, Sb, Bi, Au, Cd, Al, Si, Ge, Co, Ni, P, Cr, Se, Te, oxides thereof, or combinations thereof, in an amount less than 25% weight basis.

3) The function module according to claim 1, wherein the electrical connector is a crimp connector.

4) The function module according to claim 2, wherein the electrical connector is a crimp connector.

5) The function module according to claim 1, wherein the functional member is a foil composite and/or comprises one or more foil layers.

6) The function module according to claim 1, wherein the at least one aluminum conductor trace is a mechanical structured trace.

7) The function module according to claim 1, wherein the solder connection prevents or delays formation of an oxide layer on the at least one aluminum conductor trace within the piercing area.

8) The function module according to claim 1, wherein the form-fit connection is formed between the functional member and the electrical connector within the piercing area to provide a mechanical strain relief for the solder connection; and/or the solder connection between the functional member and the electrical connector within the piercing area provides a mechanical strain relief for the form-fit connection.

9) The function module according to claim 1, wherein the solder connection comprises solder material positioned between the functional member and the electrical connector, wherein the solder material seals gaps at penetration edges between the at least one piercing member and the at least one aluminum conductor trace.

10) The function module according to claim 1, wherein the function module is a cell connector for electrical energy storage cells.

11) The function module according to claim 1, wherein the function module is an electrical heating device.

12) A method for producing the function module according to claim 1, comprising steps of: providing the functional member having the at least one aluminum conductor trace; providing the electrical connector having the at least one piercing member; piercing the at least one piercing member of the electrical connector through the at least one aluminum conductor trace within the piercing area such that an electrically conductive form-fit connection between the piercing member of the electrical connector and the at least one aluminum conductor trace is established; and soldering together the functional member and the electrical connector within the piercing area using a solder material and a surface activation composition.

13) The method according to claim 12, wherein the method comprises: depositing or printing, the surface activation composition onto the functional member and/or onto the at least one aluminum conductor trace within the piercing area; and depositing or printing the solder material onto the surface activation composition within the piercing area.

14) The method according to claim 12, wherein the at least one piercing member of the electrical connector is pierced through the surface activation composition and/or the solder material before or at the same time the at least one piercing member of the electrical connector is pierced through the at least one aluminum conductor trace.

15) The method according to claim 12, wherein the method comprises: heating the piercing area after the surface activation composition and/or the solder material is deposited; and/or heating the piercing area after the at least one piercing member of the electrical connector is pierced through the eat least one aluminum conductor trace.

16) The method according to claim 12, wherein the surface activation composition comprises: an aqueous solvent or a mixed aqueous solvent; and/or an organic amine; and/or a fatty acid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Preferred embodiments of these teachings are explained and described in more detail below with reference to the accompanying drawings.

[0028] FIG. 1 shows an embodiment of the function module.

[0029] FIG. 2 shows a functional member of the function module in a schematic top view.

[0030] FIG. 3 shows the functional member of FIG. 2 in a schematic side view.

[0031] FIG. 4 shows the functional member of FIG. 2 after deposition of a surface activation composition in a schematic side view.

[0032] FIG. 5 shows the functional member of FIG. 2 after deposition of a solder material in a schematic side view.

[0033] FIG. 6 shows the functional member of FIG. 2 just before the piercing members are pierced through the aluminum conductor traces.

DETAILED DESCRIPTION

[0034] According to FIG. 1, the function module 10 comprises a functional member 12, wherein the functional member 12 is a foil composite and comprises one or multiple foil layers. The function module 10 further comprises an electrical connector 14, wherein the electrical connector 14 is a metallic crimp connector. A plug 16 is attached to the electrical connector 14.

[0035] The function module 10 can be, for instance, a cell connector for electrical energy storage cells or an electrical heating device.

[0036] The bottom layer 18 of the functional member 12 is a thin plastic carrier foil 18. The carrier foil 18 carries one or multiple aluminum conductor traces 20a-20e. The aluminum conductor traces 20a-20e are mechanical structured traces 20a-20e that are produced from an aluminum layer by mechanically removing the aluminum material. The aluminum conductor traces 20a-20e are covered by a thin plastic cover foil 22. The cover foil 22 does not extend over the entire length of the functional member 12. A piercing area 24 is not covered by the cover foil 22.

[0037] The electrical connector 14 has one or multiple piercing members 26a-26e. The piercing members 26a-26e are configured to pierce through the aluminum conductor traces 20a-20e in an electrically conductive manner and provide a form-fit connection between the functional member 12 and the electrical connector 14 within the piercing area 24. Even if it is not shown, the tips of the piercing members 26a-26e can be bent over on the back of the functional member 12 to secure the crimp and prevent the crimp from becoming detached. Additionally, the functional member 12 and the electrical connector 14 can be joined together within the piercing area 24 by means of a solder connection.

[0038] The form-fit connection between the functional member 12 and the electrical connector 14 within the piercing area 24 provides a mechanical strain relief for the solder connection. The solder connection between the functional member 12 and the electrical connector 14 within the piercing area 24 provides a mechanical strain relief for the form-fit connection.

[0039] The solder connection comprises solder material positioned between the functional member 12 and the electrical connector 14, wherein the solder material seals gaps at penetration edges between the piercing members 26a-26e and the aluminum conductor traces 20a-20e and thereby prevents or at least delays the formation of an oxide layer on the aluminum conductor traces 20a-20e within the piercing area 24 irrespective of temperature, humidity and/or aging.

[0040] The solder connection between the functional member 12 and the electrical connector 14 within the piercing area 24 is based on a surface activation composition. The surface activation composition comprises an aqueous solvent or a mixed aqueous solvent and/or an organic amine and/or a fatty acid and/or a filler selected from the group consisting of Sn, Ag, Zn, Cu, In, Sb, Bi, Au, Cd, Al, Si, Ge, Co, Ni, P, Cr, Se, Te, oxides thereof, or combinations thereof, preferably in an amount less than 25% weight basis.

[0041] FIGS. 2 to 6 show consecutive steps of a method for producing a function module 10 for electrical applications, namely the function module 10 shown in FIG. 1.

[0042] As shown in FIGS. 2 and 3, first a functional member 12 having multiple parallel aluminum conductor traces 20a-20e is provided. The functional member 12 is a foil composite and comprises multiple foil layers. The bottom layer of the functional member 12 is a thin plastic carrier foil 18. The carrier foil 18 carries the multiple aluminum conductor traces 20a-20e. The aluminum conductor traces 20a-20e are covered by a thin plastic cover foil 22. The cover foil 22 does not extend over the entire length of the functional member 12. A piercing area 24 is not covered by the cover foil 22.

[0043] Next, as shown in FIG. 4, a surface activation composition 28 is deposited onto the aluminum conductor traces 20a-20e within the piercing area 24. Depositing the surface activation composition 28 is performed by using a printing technique. The surface activation composition 28 comprises an aqueous solvent or a mixed aqueous solvent and/or an organic amine and/or a fatty acid.

[0044] Next, as shown in FIG. 5, solder material 30 is deposited onto the surface activation composition 28 within the piercing area 24. Depositing the solder material 30 is also performed by using a printing technique. The solder material 30 is a solder paste with flux included.

[0045] After the solder material 30 has been deposited onto the surface activation composition 28, an electrical connector 14 having multiple piercing members 26a-26e is positioned such that the piercing members 26a-26e are just above the piercing area 24, as shown in FIG. 6. Then, the piercing members 26a-26e of the electrical connector 14 are pierced through the surface activation composition 28, the solder material 30 and the aluminum conductor traces 20a-20e within the piercing area 24 such that an electrically conductive form-fit connection between the piercing members 26a-26e of the electrical connector 14 and the aluminum conductor traces 20a-20e is established.

[0046] Afterwards, the functional member 12 and the electrical connector 14 are soldered together within the piercing area 24 by heating the solder material 30 and the surface activation composition 28.

[0047] It is understood that the method or process steps described herein can be performed in virtually any order. Moreover, one or more of the method or process steps can be combined with other steps; can be omitted or eliminated; can be repeated; and/or can separated into individual or additional steps.

[0048] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with these teachings, invention, its principles, and its practical application. The above description is intended to be illustrative and not restrictive. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use.

[0049] Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to this description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0050] Plural elements or steps can be provided by a single integrated element or step. Alternatively, a single element or step might be divided into separate plural elements or steps.

[0051] The disclosure of “a” or “one” or “an” to describe an element or step is not intended to foreclose additional elements or steps. For example, disclosure of “an electrical connector” does not limit the teachings to a single electrical connector. Instead, for example, disclosure of “an electrical connector” may include “one or more electrical connectors.”

[0052] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings.

[0053] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0054] The teachings and invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

[0055] Any of the elements, components, regions, layers and/or sections disclosed herein are not necessarily limited to a single embodiment. Instead, any of the elements, components, regions, layers and/or sections disclosed herein may be substituted, combined, and/or modified with any of the elements, components, regions, layers and/or sections disclosed herein to form one or more embodiments that may be not be specifically illustrated or described herein.

[0056] The disclosures of all articles and references, including patent applications and publications, testing specifications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

LIST OF REFERENCE SIGNS

[0057] 10 function module

[0058] 12 functional member

[0059] 14 electrical connector

[0060] 16 plug

[0061] 18 carrier foil

[0062] 20a-20e aluminum conductor traces

[0063] 22 cover foil

[0064] 24 piercing area

[0065] 26a-26e piercing members

[0066] 28 surface activation composition

[0067] 30 solder material